Seam construction using radio frequency welding and tape

ABSTRACT

A process of constructing an air tight and water tight seam, comprising cutting a sheet of selected material into two or more panels, sealing the panels at respective selected edges using an ultrasonic machine to form a seam, overlaying the seam with a tape made of the same selected material, and sealing the tape and seam using a radio frequency (RF) welding machine.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. patent applicationSer. No. 16/927,989, filed Jul. 14, 2020, which is a continuation ofU.S. patent application Ser. No. 15/460,886, filed Mar. 16, 2017, nowU.S. Pat. No. 10,751,948, issued Aug. 25, 2020, which claims benefit ofpriority to U.S. Provisional Patent Application No. 62/310,326, filedMar. 18, 2016, which are hereby incorporated by reference in theirentireties.

TECHNICAL FIELD

Embodiments of the present invention generally relate to seamconstruction, and more specifically to a seam construction using radiofrequency welding with a tape finished construction.

BACKGROUND OF THE INVENTION

Radio frequency (RF) welding is a method for joining thin sheets ofcertain plastics with chemical dipoles together. Some of these plasticmaterials include thermoplastics such as polyvinylchloride (PVC),polyurethane (PU), thermoplastic polyurethane (TPU), thermoplasticelastomers (TPE), etc. The materials can be heated with high frequencyelectromagnetic waves. The method uses high frequency, usually between13 and 120 MHz, electromagnetic energy to fuse the materials. As such,RF welding may also be known as high frequency (HF) welding ordielectric welding. Generally, a rapidly alternating electric field isset up between two metal welding plates or bars, where two pieces of thematerial are placed. The electric field causes the polar molecules foundin the material to oscillate and orient themselves with respect to thefield. The energy generated by this process causes a temperatureincrease (heat) which results in melting of the material. The weldingplates or bars are then pressed together, forming a weld between the twopieces.

Because RF welding is better than conventional stitching used inconstructing seams, RF welding has often been used to construct seamsfor various types of products, including clothing garments, bags, tents,etc., just to name a few examples. It is advantageous, therefore, toconstruct seams that are strong, air tight, and water tight.

However, the quality of welds or bonds formed by the RF welding processis usually a result of a complicated combination of machine parameters(power output, frequency), the temperature profile and bar pressure, andthe material type and thickness. Achieving a strong and consistentlyleak-proof seal using RF welding can be difficult.

Therefore, it would be highly beneficial to provide systems and methodsfor seam construction that provide seams that are consistently strong,air tight, and water tight.

SUMMARY OF THE INVENTION

Provided herein are embodiments of methods for seam construction thatprovide seams that are consistently strong, air tight, and water tight,and more specifically methods for seam construction using thecombination of RF welding and tape finish. The methods of constructing aconsistently strong, air tight and water tight seam may include cuttinga sheet of material made of a selected material into two panels, sealingthe two panels at a respective selected edge of each of the two panelsusing an ultrasonic machine, thus forming a seam, overlaying the seamwith a section of tape made of the selected material, and sealing thesection of tape and the seam using a radio frequency (RF) weldingmachine.

This summary and the following detailed description are merelyexemplary, illustrative, and explanatory, and are not intended to limit,but to provide further explanation of the invention as claimed.Additional features and advantages of the invention will be set forth inthe descriptions that follow, and in part will be apparent from thedescription, or may be learned by practice of the invention. Theobjectives and other advantages of the invention will be realized andattained by the structure particularly pointed out in the writtendescription, claims and the appended drawings and support materials.

BRIEF DESCRIPTION OF THE DRAWINGS

Understanding this invention will be facilitated by the followingdetailed description of the preferred embodiments considered inconjunction with the accompanying drawings, in which like numerals referto like parts. Note, however, that the drawings are not drawn to scale.

FIG. 1 illustrates an exemplary flowchart of a seam construction processaccording to an embodiment of this invention.

FIG. 2 illustrates an exemplary top rear view of a seam for panels of a70D material according to an embodiment of this invention.

FIG. 3 illustrates an exemplary perspective rear view of a seam forpanels of a 70D material according to an embodiment of this invention.

FIG. 4 illustrates an exemplary top front view of a seam for panels of a70D material according to an embodiment of this invention.

FIG. 5 illustrates an exemplary perspective front view of a seam forpanels of a 70D material according to an embodiment of this invention.

FIG. 6 illustrates an exemplary top rear view of a seam for panels of a20D material according to an embodiment of this invention.

FIG. 7 illustrates an exemplary perspective rear view of a seam forpanels of a 20D material according to an embodiment of this invention.

FIG. 8 illustrates an exemplary top front view of a seam for panels of a20D material according to an embodiment of this invention.

FIG. 9 illustrates an exemplary perspective front view of a seam forpanels of a 20D material according to an embodiment of this invention.

FIG. 10 illustrates exemplary results of an exemplary test usingstitching (e.g., 8 stiches per inch) on a 70D material according to anembodiment of this invention.

FIG. 11 illustrates exemplary results of an exemplary test using theprocess of the invention on a 70D material according to an embodiment ofthis invention.

FIG. 12 illustrates exemplary results of another exemplary test usingstitching (e.g., 8 stiches per inch) on a 70D material according to anembodiment of this invention.

FIG. 13 illustrates exemplary results of another exemplary test usingthe process of the invention on a 70D material according to anembodiment of this invention.

FIG. 14 illustrates exemplary results of another exemplary test usingstitching (e.g., 8 stiches per inch) on a 70D material according to anembodiment of this invention.

FIG. 15 illustrates exemplary results of another exemplary test usingthe process of the invention on a 70D material according to anembodiment of this invention.

FIG. 16 illustrates exemplary results of an exemplary test usingstitching (e.g., 8 stiches per inch) on a 20D material according to anembodiment of this invention.

FIG. 17 illustrates exemplary results of an exemplary test using theprocess of the invention on a 20D material according to an embodiment ofthis invention.

FIG. 18 illustrates exemplary results of another exemplary test usingstitching (e.g., 8 stiches per inch) on a 20D material according to anembodiment of this invention.

FIG. 19 illustrates exemplary results of another exemplary test usingthe process of the invention on a 20D material according to anembodiment of this invention.

FIG. 20 illustrates exemplary results of another exemplary test usingstitching (e.g., 8 stiches per inch) on a 20D material according to anembodiment of this invention.

FIG. 21 illustrates exemplary results of another exemplary test usingthe process of the invention on a 20D material according to anembodiment of this invention.

FIG. 22 illustrates a chart showing the results of the exemplary testsof FIGS. 10-21 according to an embodiment of this invention.

FIG. 23A illustrates an exemplary front view of a jacket according to anembodiment of this invention.

FIG. 23B illustrates an exemplary back view of a jacket according to anembodiment of this invention.

FIG. 24 illustrates an exemplary perspective view of a rucksackaccording to an embodiment of this invention.

FIG. 25 illustrates an exemplary top view of a sleeping bag according toan embodiment of this invention.

FIG. 26 illustrates an exemplary perspective view of a tent according toan embodiment of this invention.

DETAILED DESCRIPTION

The drawings, support materials, and related descriptions of theembodiments have been simplified to illustrate elements that arerelevant for a clear understanding of these embodiments, whileeliminating various other elements found in conventional seamconstruction and RF welding methods. Those of ordinary skill in the artmay thus recognize that other elements and/or steps are desirable and/orrequired in implementing the embodiments that are claimed and described.But, because those other elements and steps are well known in the art,and because they do not necessarily facilitate a better understanding ofthe embodiments, they are not discussed. This disclosure is directed toall applicable variations, modifications, changes, and implementationsknown to those skilled in the art. As such, the following detaileddescriptions are merely illustrative and exemplary in nature and are notintended to limit the embodiments of the subject matter or the uses ofsuch embodiments. As used in this application, the terms “exemplary” and“illustrative” mean “serving as an example, instance, or illustration.”Any implementation described as exemplary or illustrative is not meantto be construed as preferred or advantageous over other implementations.Further, there is no intention to be bound by any expressed or impliedtheory presented in the preceding background of the invention, briefsummary, or the following detailed description.

In the following description and in the figures, like elements areidentified with like reference numerals. The use of “e.g.,” “etc.,” and“or” indicates non-exclusive alternatives without limitation, unlessotherwise noted. The use of “including” or “includes” means “including,but not limited to,” or “includes, but not limited to,” unless otherwisenoted.

As used herein, the term “and/or” placed between a first entity and asecond entity means one of (1) the first entity, (2) the second entity,and (3) the first entity and the second entity. Multiple entities listedwith “and/or” should be construed in the same manner, i.e., “one ormore” of the entities so conjoined. Other entities may optionally bepresent other than the entities specifically identified by the “and/or”clause, whether related or unrelated to those entities specificallyidentified. Thus, as a non-limiting example, a reference to “A and/orB”, when used in conjunction with open-ended language such as“comprising” can refer, in one embodiment, to A only (optionallyincluding entities other than B); in another embodiment, to B only(optionally including entities other than A); in yet another embodiment,to both A and B (optionally including other entities). These entitiesmay refer to elements, actions, structures, steps, operations, values,and the like.

Referring now to the figures, wherein like reference numerals designateidentical or corresponding parts throughout the several views andembodiments, methods and processes in accordance with the presentinvention are illustrated in FIGS. 1 to 26.

Referring to FIG. 1, an exemplary flowchart of a process 100 accordingto some embodiments of the invention is illustrated. In some exemplaryoperations, the steps for constructing a consistently strong, air tight,and water tight seam may generally include cutting a sheet of materialmade of a selected material into panels (Step 110), sealing the panelstogether at respective edges using an ultrasonic sealing machine (Step120), forming a seam. The new seam is then overlaid with a section of afabric tape, which has been coated with polyurethane (PU), thermoplasticpolyurethane (TPU), Polyvinyl Chloride (PVC), Ethylene-Vinyl Acetate(EVA), Polytetrafluoroethylene (PTFE), or a combination thereof, or withother suitable material (Step 130). An area adjacent to both sides andalong the length of the seam may also be coated with polyurethane (PU),thermoplastic polyurethane (TPU), Polyvinyl Chloride (PVC),Ethylene-Vinyl Acetate (EVA), Polytetrafluoroethylene (PTFE), or acombination thereof, or with other suitable material. The tape and theseam are then sealed using an RF welding machine (Step 140).

In Step 110, a sheet of a selected material may be cut into panels ofdesired shapes and sizes, based on the specifications of the desiredproducts. The products may include, for example, jackets, pants, backpacks, duffle bags, dry bags, tents, sleeping bags, and so on, as shown,for example, in FIGS. 23-26. Any conventional fabric cutting machineknown in the art may be used for the cutting.

Once the sheet of the selected material has been cut into panels, andthe edges that need to be sealed have been determined, in Step 120, insome embodiments, the edges may be sealed together using an ultrasonicsealing machine. As a result, a new seam is formed at the respectiveedges of the panels. FIGS. 2 and 3 illustrate respectively an exemplarytop rear view and an exemplary perspective rear view of two sealed 70Dfabric panels 201 and 202, forming a seam 200. FIGS. 6 and 7 illustraterespectively an exemplary top front view and an exemplary perspectivefront view of the sealed 20D fabric panels 601 and 602, forming a seam600. Although examples of 20D and 70D materials are illustrated, any100D and lighter, for example, as low as 5D material may be used.

Any conventional ultrasonic sealing machine known in the art may beused. With ultrasonic sealing, the heat required for melting isgenerated inside the material, for example, not by heat input from theoutside as is the case with heat sealing.

In Step 130, in some embodiments, a tape made of the same material asthe material of the fabric panels may be used. The tape may be coatedwith polyurethane (PU), thermoplastic polyurethane (TPU), PolyvinylChloride (PVC), Ethylene-Vinyl Acetate (EVA), Polytetrafluoroethylene(PTFE), or a combination thereof. Other suitable coating materials mayalso be used. The tape may be coated on the side that will be coupled,or bonded, to the seam, as described below.

An area adjacent to both sides and along the length of the seam formedin Step 120 may also be coated with polyurethane (PU), thermoplasticpolyurethane (TPU), Polyvinyl Chloride (PVC), Ethylene-Vinyl Acetate(EVA), Polytetrafluoroethylene (PTFE), or a combination thereof. Othersuitable coating materials may also be used. The coated tape, or morespecifically, a section of the tape, may then be overlaid over thecoated seam. For example, FIG. 4 illustrates an exemplary tape section400 overlaying seam 200. FIG. 8 illustrates an exemplary tape section800 overlaying seam 600.

In Step 140, in some embodiments, the tape and the seam are then sealedusing an RF welding machine. Any conventional RF welding machine knownin the art may be used. As a result, a strong, air tight (airproof) andwater tight (waterproof) seam is constructed. FIGS. 4 and 5 illustratean exemplary top front view and an exemplary perspective front view theseal 200 and tape 400 welded (or sealed, or bonded) using a conventionalRF welding machine. FIGS. 8 and 9 illustrate an exemplary top front viewand an exemplary perspective front view the seal 600 and tape 800 welded(or sealed, or bonded) using a conventional RF welding machine.

Testing has been performed to show the superior strength of seamsconstructed using the process of the invention, as compared to seamsconstructed using stitching. FIGS. 10-22 illustrate exemplary testresults performed using 20D and 70D materials. The tests include, forexample, Breaking Force, Breaking Strength, Elongation at Break,Elongation at Rupture, Breaking Time, Bursting Strength, Break-offForce, Tensile Strength, Tensile Rate, Break-off Strength, NominalTensile Strength, and Initial Modulus.

FIG. 10 illustrates, according to some embodiments, exemplary results ofan exemplary test using stitching (e.g., 8 stiches per inch) on a 70Dmaterial.

FIG. 11 illustrates, according to some embodiments, exemplary results ofan exemplary test using the process of the invention on a 70D material.

FIG. 12 illustrates, according to some embodiments, exemplary results ofanother exemplary test using stitching (e.g., 8 stiches per inch) on a70D material.

FIG. 13 illustrates, according to some embodiments, exemplary results ofanother exemplary test using the process of the invention on a 70Dmaterial.

FIG. 14 illustrates, according to some embodiments, exemplary results ofanother exemplary test using stitching (e.g., 8 stiches per inch) on a70D material.

FIG. 15 illustrates, according to some embodiments, exemplary results ofanother exemplary test using the process of the invention on a 70Dmaterial.

FIG. 16 illustrates, according to some embodiments, exemplary results ofan exemplary test using stitching (e.g., 8 stiches per inch) on a 20Dmaterial.

FIG. 17 illustrates, according to some embodiments, exemplary results ofan exemplary test using the process of the invention on a 20D material.

FIG. 18 illustrates, according to some embodiments, exemplary results ofanother exemplary test using stitching (e.g., 8 stiches per inch) on a20D material.

FIG. 19 illustrates, according to some embodiments, exemplary results ofanother exemplary test using the process of the invention on a 20Dmaterial.

FIG. 20 illustrates, according to some embodiments, exemplary results ofanother exemplary test using stitching (e.g., 8 stiches per inch) on a20D material.

FIG. 21 illustrates, according to some embodiments, exemplary results ofanother exemplary test using the process of the invention on a 20Dmaterial.

FIG. 22 illustrates, according to some embodiments, a chart showing theresults of the exemplary tests of FIGS. 10-21.

FIGS. 23-26 illustrate, according to some embodiments, exemplary uses ofthe invention process on exemplary products. It should be noted thatthese are only exemplary products shown for illustration purpose only,and the invention process is not limited to these products. FIG. 23Aillustrates an exemplary front view 2300 of a jacket. FIG. 23Billustrates an exemplary back view 2310 of a jacket. The exemplary seams2301 and 2311 shown in dark, bold lines may be formed using the processof the invention. Note that although the numeric labels 2310 and 2311are shown pointing to respective exemplary seams, other seams shown indark, bold lines may be formed using the process of the invention.

FIG. 24 illustrates, according to some embodiments, an exemplaryperspective view 2400 of a rucksack or backpack. The exemplary seams2410 shown in dark, bold lines may be formed using the process of theinvention. Note that although the numeric label 2410 is shown pointingto respective exemplary seam, other seams shown in dark, bold lines maybe formed using the process of the invention.

FIG. 25 illustrates, according to some embodiments, an exemplary topview 2500 of a sleeping bag. The exemplary seams 2510 shown in dark,bold lines may be formed using the process of the invention. Note thatalthough the numeric label 2510 is shown pointing to respectiveexemplary seam, other seams shown in dark, bold lines may be formedusing the process of the invention.

FIG. 26 illustrates, according to some embodiments, an exemplaryperspective view 2600 of a tent. The exemplary seams 2610 shown in dark,bold lines may be formed using the process of the invention. Note thatalthough the numeric label 2610 is shown pointing to respectiveexemplary seam, other seams shown in dark, bold lines may be formedusing the process of the invention.

The previous description of the disclosure is provided to enable anyperson skilled in the art to make or use the disclosure. Variousmodifications to the disclosure will be readily apparent to thoseskilled in the art, and the generic principles defined herein may beapplied to other variations without departing from the scope of thedisclosure. Thus, the disclosure is not intended to be limited to theexamples and designs described herein, but is to be accorded the widestscope consistent with the principles and novel features disclosedherein.

what is claimed is:
 1. A process of constructing an air tight and watertight seam, comprising: cutting a sheet of material made of a selectedfirst material into two panels; sealing the two panels at a respectiveselected edge of each of the two panels using an ultrasonic machine,forming a seam; overlaying the seam with a section of tape made of theselected first material; and sealing the section of tape and the seamusing a radio frequency (RF) welding machine.
 2. The process of claim 1,wherein the section of tape is further coated with a second material onone side of the section of tape before the overlaying step.
 3. Theprocess of claim 2, wherein the second material is polyurethane (PU). 4.The process of claim 2, wherein the second material is thermoplasticpolyurethane (TPU).
 5. The process of claim 2, wherein the secondmaterial is one of Polyvinyl Chloride (PVC), Ethylene-Vinyl Acetate(EVA), Polytetrafluoroethylene (PTFE), or a combination thereof.
 6. Theprocess of claim 2, wherein the overlaying step comprises overlaying thecoated side of the section of tape against the seam.
 7. The process ofclaim 1, wherein an area adjacent to both sides of the seam and along alength of the seam is further coated a third material before theoverlaying step.
 8. The process of claim 7, wherein the third materialis polyurethane (PU).
 9. The process of claim 7, wherein the thirdmaterial is thermoplastic polyurethane (TPU).
 10. The process of claim7, wherein the third material is one of Polyvinyl Chloride (PVC),Ethylene-Vinyl Acetate (EVA), Polytetrafluoroethylene (PTFE), or acombination thereof.
 11. The process of claim 1, wherein the panels arecut based on one or more specifications of a desired product.
 12. Amanufacturing system for constructing an air tight and water tight seam,the manufacturing system constructing the air tight and water tight seamcomprising the steps of: cutting a sheet of material made of a selectedfirst material into two panels; sealing the two panels at a respectiveselected edge of each of the two panels using an ultrasonic machine,forming a seam; overlaying the seam with a section of tape made of theselected first material; and sealing the section of tape and the seamusing a radio frequency (RF) welding machine.
 13. The manufacturingsystem of claim 12, wherein the section of tape is further coated with asecond material on one side of the section of tape before the overlayingstep.
 14. The manufacturing system of claim 13, wherein the secondmaterial is polyurethane (PU).
 15. The manufacturing system of claim 13,wherein the second material is one of polyurethane (PU), thermoplasticpolyurethane (TPU), Polyvinyl Chloride (PVC), Ethylene-Vinyl Acetate(EVA), Polytetrafluoroethylene (PTFE), or a combination thereof.
 16. Themanufacturing system of claim 13, wherein the overlaying step comprisesoverlaying the coated side of the section of tape against the seam. 17.The manufacturing system of claim 12, wherein an area adjacent to bothsides of the seam and along a length of the seam is further coated athird material before the overlaying step.
 18. The manufacturing systemof claim 17, wherein the third material is polyurethane (PU).
 19. Themanufacturing system of claim 17, wherein the third material is one ofpolyurethane (PU), thermoplastic polyurethane (TPU), Polyvinyl Chloride(PVC), Ethylene-Vinyl Acetate (EVA), Polytetrafluoroethylene (PTFE), ora combination thereof.
 20. The manufacturing system of claim 12, whereinthe panels are cut based on one or more specifications of a desiredproduct.